LED luminaire

• US 20060267028A1
• Filed: 07/31/2006
• Published: 11/30/2006
• Est. Priority Date: 10/09/2003
• Status: Active Grant

• Current Assignee: Permlight Products Inc
• Original Assignee: Permlight Products Inc
• Inventors: Lynch, Manuel, Fraitag, Leonard
• Granted Patent: US 7,582,911 B2
• Time in Patent Office: Days
• US Class Current: 257/79
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21S 4/10 with light sources attached to loose electric cables, e.g. Christmas tree lights
• CPC Class Codes: F21S 8/024 intended to be recessed in a wall or like vertical structure, e.g. building facade
• CPC Class Codes: F21S 8/035 by means of plugging into a wall outlet, e.g. night light
• CPC Class Codes: F21V 11/00 Screens not covered by groups F21V1/00, F21V3/00, F21V7/00 or F21V9/00 characterised by cooling arrangements F21V29/502
• CPC Class Codes: F21V 19/001 the light sources being semiconductors devices, e.g. LEDs
• CPC Class Codes: F21V 23/007 enclosed in a casing
• CPC Class Codes: F21V 23/0442 activated by means of a sensor, e.g. motion or photodetectors
• CPC Class Codes: F21V 23/0471 the sensor detecting the proximity, the presence or the movement of an object or a person
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 33/006 General building constructions or finishing work for buildings, e.g. roofs, gutters, stairs or floors; Garden equipment; Sunshades or parasols
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/3025 Electromagnetic shielding
• CPC Class Codes: H02G 3/20 Ceiling roses or other lighting sets

Abstract

A modular light emitting diode (LED) mounting configuration is provided including a light source module having a plurality of pre-packaged LEDs arranged in a serial array. The module is connected to a heat dissipating plate configured to mount to an electrical junction box. Thus, heat from the LEDs is conducted to the heat dissipating plate and to the junction box. A sensor is configured to detect environmental parameters and a driver is configured to illuminate the LEDs in response to the environmental parameters, thereby selectively configuring the LEDs to function in a wide variety of useful applications.

Claims

1. A lighting apparatus, comprising:

a light emitting diode (LED) module having;

at least one LED;

a dielectric member; and

a plurality of electrically conductive contacts disposed on the dielectric member, the contacts configured to mount the at least one LED so that an electrical current path is defined between a first contact and a second contact, and the at least one LED is disposed along the current path;

a heat conductive member having a first side and a second side; and

a power driver adapted to receive an electrical input power, condition the power to a desired power configuration, and output conditioned power;

wherein the LED module is attached to the first side of the heat conductive member and the power driver is attached to the second side of the heat conductive member, and the driver is electrically connected to the LED module so that conditioned power is supplied across the first and second contacts.

2. A lighting apparatus as in claim 1, wherein a pair of fasteners connect the LED module to the first side of the heat conductive member, wherein a fastener engages respective ones of the first and second contacts of the LED module, and wherein electrical power from the driver is delivered through the fasteners to the LED module.

3. A lighting apparatus as in claim 2, wherein the fasteners comprise threaded fasteners.

4. A lighting apparatus as in claim 3, wherein the fasteners each comprise a threaded shank and a head, and the head is adapted to make electrical contact with a respective first or second contact.

5. A lighting apparatus as in claim 4, wherein the LED module comprises a body portion, and the dielectric member is disposed on the body portion.

6. A lighting apparatus as in claim 5, wherein a pair of apertures are formed through the LED module body, and the fasteners extend through the apertures.

7. A lighting apparatus as in claim 4, wherein the fastener shanks extend through the heat conductive member, and additionally comprising an insert disposed between each fastener shank and the heat conductive member, the insert being electrically non-conductive so as to electrically insulate the fastener from the heat conductive member.

8. A lighting apparatus as in claim 7, wherein the heat conductive member has a heat conductivity at least about 100 W/mK.

9. A lighting apparatus as in claim 7, wherein the driver comprises a pair of threaded receivers adapted to output conditioned power, and the fasteners are adapted to threadingly engage the driver receivers so that power is supplied directly from the driver to the fasteners and further to the LED module.

10. A lighting apparatus as in claim 7 additionally comprising a pair of flexible conductors attached to an output of the power driver and to respective LED module fastener shanks so as to supply power from the driver to the fasteners and further to the LED module.

11. A lighting apparatus as in claim 2, wherein the first and second sides of the heat conductive member generally oppose one another and the fasteners extend through the heat conductive member and engage corresponding receivers of the power driver, the receivers adapted to output conditioned power so that power is supplied from the driver to the fasteners and further to the LED module.

12. A lighting apparatus as in claim 11, wherein the fasteners simultaneously attach the LED module and the power driver to the heat conductive member.

13. A lighting apparatus as in claim 12 additionally comprising non-conductive inserts fit about shanks of the fasteners so as to electrically insulate the fasteners from the heat conductive member.

14. A lighting apparatus as in claim 13, wherein the fasteners and driver receivers are threaded so as to threadingly engage one another.

15. A lighting apparatus as in claim 12 additionally comprising a second module attached to the heat conductive member.

16. A lighting apparatus as in claim 15 additionally comprising a second power driver attached to the heat conductive member and adapted to supply power to the second module.

17. A lighting apparatus as in claim 16, wherein the second module comprises a condition sensor.

18. A lighting apparatus as in claim 15, wherein the second module is electrically connected to the power driver, and the power driver is adapted to simultaneously provide power to the LED module and the second module.

19. A lighting apparatus as in claim 18, wherein the second module comprises an LED module.

20. A lighting apparatus as in claim 18, wherein the second module comprises a condition sensor.

21. A lighting apparatus as in claim 20, wherein the driver comprises a controller adapted to control the LED module at least partially in response to sensor inputs.

22. A lighting apparatus as in claim 12, wherein the driver comprises a controller adapted to control light intensity of the LED module.

23. A lighting apparatus as in claim 12 additionally comprising a cover fit generally over the LED module, the cover having an aperture adapted to channel light from the LED module.

24. A lighting apparatus as in claim 23 additionally comprising a lens disposed across the aperture.

25. A lighting apparatus, comprising:

a light emitting diode (LED) module having;

at least one LED;

a dielectric member having a first side and a second side;

a plurality of electrically conductive contacts disposed on the first side of the dielectric member, the contacts configured to mount the at least one LED so that an electrical current path is defined between a first contact and a second contact, and the at least one LED is disposed along the current path; and

a body disposed on the second side of the dielectric member, the body having a first aperture at or adjacent the first contact and a second aperture at or adjacent the second contact, and the first and second apertures extend through the dielectric member;

a mount member having a first side, a second side, and first and second mount member apertures;

a power driver adapted to receive an electrical input power, condition the power to a desired power configuration, and output the conditioned power; and

first and second elongate fasteners, the first and second fasteners each having a head portion, an elongate shank, and being electrically conductive;

wherein the LED module is attached to the first side of the mount member so that the first and second body apertures substantially align with the first and second mount member apertures, and the first and second elongate fasteners extend through the aligned first and second body and mount member apertures, respectively, so that the fastener head portions engage and electrically communicate with the first and second contacts, respectively, and define an electrical current path through the mount member, across the contacts and at least one LED, and back through the mount member; and

wherein the driver is electrically connected to the shanks of the first and second fasteners, respectively, so as to deliver the conditioned power to the LED module through the fasteners.

26. A lighting apparatus as in claim 25, wherein the mount member has a heat conductivity at least about 75 W/mK, and the LED module is connected to the mount member so that heat from the LEDs flows to the contacts, further to the body and then into the mount member.

27. A lighting apparatus as in claim 26 additionally comprising a mounting box having a plurality of sides defining a cavity therewithin, at least one of the sides having a port configured to provide access to the cavity, and the mount member engages a side of the mounting box.

28. A lighting apparatus as in claim 27, wherein the mounting box has a heat conductivity of at least 75 W/mK so that heat from the mount member flows to the mounting box.

29. A lighting apparatus as in claim 25, wherein the power driver is mounted onto the second side of the mount member.

30. A lighting apparatus as in claim 29, wherein the mount member is sandwiched between the power driver and the LED module.

31. A lighting apparatus as in claim 30, wherein the power driver comprises first and second receivers adapted to receive the first and second fasteners, respectively, and the power driver is configured to output conditioned power to the first and second receivers.